Ultrasonic rigid horn assembly

ABSTRACT

A versatile rigid horn assembly for distributing ultrasonic energy from at least one source to a plurality of spaced work areas is provided. This rigid horn assembly includes an elongated tool holder having an input region at one end and an output region at the other end. The tool holder is a horn of suitable metal and will have a length of at least one acoustic half wavelength, or any desired number of integral half wavelengths. Secured to and extending from the output end are rigid tool members, each of which is a horn and has a length of at least one acoustical half wavelength. Tool members may have lengths of integral half wavelengths, it being understood that tool members need not necessarily be of the same shape or length. The drawings illustrate various arrangements of tool members. The output end of a tool holder has means permitting attachment of a plurality of tool members, the means being arranged so that one or more various tool members may be disposed to provide different tool member patterns. The means for attaching a tool member to a tool holder includes threaded metal members each of which may be a threaded stud extending into a tapped recess in the tool holder or elongated bolts each having an enlarged head disposed in bores extending longitudinally of the tool holder and having an interior shouldered part for each bore. Alternatively, a tool member may include an integral threaded boss, or the tool holder and tools may be of brazable material and secured by brazing.

United States Patent [191 Davis 1 1 ULTRASONIC RIGID HORN ASSEMBLY [75]Inventor: Paul H. Davis, St. Charles, 111.

[73] Assignee: Dukane Corporation, St. Charles, 111.

[22] Filed: Oct. 17, 1974 [21] Appl. N0.: 515,504

Related US. Patent Documents Reissue of:

[64] Patent N0.: 3,780,926

Issued: Dec. 25, 1973 Appl. N0.: 259,023

Filed: June 2, 1972 [52] US. Cl. 228/1; 156/731; 228/110 [51] Int. Cl.B23K l/06; 823K 5/20 [58] Field of Search 228/1; 29/4701, 470.3;

[56] References Cited UNITED STATES PATENTS 3,148,293 9/1964 Jones eta1. 310/26 3,166,840 1/1965 Bancroft et a1. 310/26 X 3,209,448 10/1965Jones 29/4701 3,210,724 10/1965 Jones et a1. 310/26 X 3,440,117 4/1969Saloff et a1 l56/73.1 3,612,385 10/1971 Humpage 228/1 PrimaryExaminerRonald J. Shore Attorney, Agent, or FirmRobert L. Kahn ABSTRACTA versatile rigid horn assembly for distributing ultra- [11] E Re.28,642

[ Reissued Dec. 9, 1975 sonic energy from at least one source to aplurality of spaced work areas is provided. This rigid horn assemblyincludes an elongated tool holder having an input region at one end andan output region at the other end. The tool holder is a horn of suitablemetal and will have a length of at least one acoustic half wavelength,or any desired number of integral half wavelengths. Secured to andextending from the output end are rigid tool members, each of which is ahorn and has a length of at least one acoustical half wavelength. Toolmembers may have lengths of integral half wavelengths, it beingunderstood that tool members need not necessarily be of the same shapeor length. The drawings illustrate various arrangements of tool members.The output end of a tool holder has means permitting attachment of aplurality of tool members, the means being arranged so that one or morevarious tool members may be disposed to provide difierent tool memberpatterns. The means for attaching a tool member to a tool holderincludes threaded metal members each of which may be a threaded studextending into a tapped recess in the tool holder or elongated boltseach having an enlarged head disposed in bores extending longitudinallyof the tool holder and having an interior shouldered part for each bore.

Alternatively, a tool member may include an integral threaded boss, orthe tool holder and tools may be of brazable material and secured bybrazing.

6 Claims, 16 Drawing Figures [TRANSEUCERl RiSSUd Dec. 9, 1975 Sheet 1of4 Re. 28,642

FlG 1 [TRANSEUCER PK; 2

Reissued Dec. 9, 1975 Sheet 3 of4 Re. 28,642

FIG. 5 FIG. 6

Reissued Dec. 9, 1975 Sheet 4 of4 Re. 28,642

ULTRASONIC RIGID HORN ASSEMBLY Matter enclosed in heavy brackets Iappears in the original patent but forms no part of this reissuespecification; matter printed in italics indicates the additions made byreissue.

INTRODUCTION This invention relates to an ultrasonic rigid horn assemblyhaving enhanced functional adaptability for distributing ultrasonicenergy from one or more sources to a plurality of tool members forapplication to various work areas. The invention particularly relates toapplications of ultrasonics to plastics, such as welding, staking orinserting. As an example, welding may be accomplished by application ofultrasonic energy atpredetermined work areas. In many instances, suchwork areas are disposed at spaced intervals in desired patterns forsimultaneous treatment. The ultrasonic energy is directed to such spacedwork areas to create simultaneously a pattern of weldments or otherwork.

It is not limited to plastics working, however, and may be useful whereultrasonic energy is required at discrete locations. Thus liquid at anumber of locations may be cavitated.

It has been the practice to provide a unitary tool structure whose inputis connected to a suitable source of ultrasonic acoustic energy andwhose output is available at spaced sonic applicator regions on thetool. The sonic regions may assume a variety of forms, such as smallseparate circular or rectangular areas, all adapted to operate on thework piece and provide the desired effect at each of the sonicapplicator regions. Inasmuch as the sonic applicator regions must besupplied with ultrasonic energy, the sonic wave transmissioncharacteristics of a tool structure is determined in a substantialmanner not only by the nature of the tool structure material (usuallymetal) but also by the longitudinal and transverse dimensions of thetool structure material. Such requirements involve shaping of a toolstructure to obtain the required sonic tuning and vibration amplitude.It is, of course, well understood in this art that unless sonic energyis fed to every one of the spaced sonic energy applicator areas, thatthe desired action at the various regions to be operated upon may notoccur.

As a rule, customer requirements with regard to number and spacing ofsonic applicator regions in a tool structure differ greatly and maychange even with changes only in dimensions and number and pattern ofwork areas.

In tool making for various customer requirements, the shaping of a toolto obtain desired operation often involves difficult machiningoperations to provide the desired shapes of the various parts of a tool.Frequently, such tools can not utilize surfaces of revolution in theirmanufacture. Consequently, the shaping of a tool may require difficultmilling operations or even hand work. The various portions of a toolstructure from the sonic input part to the respective individual sonicoutputs must all have precise tuning and vibration amplitudecharacteristics.

The machining requirements for such tools are often made more expensiveby the fact that the tool metals used in ultrasonic work may be specialalloys, difficult to machine, such as titanium or monel. Titanium, inparticular, is very expensive as a raw material. in some instances,special thicknesses of metal plates for tool fabrication are required.

The resulting tool is useful for one particular job and rarely isadaptable for a different pattern of work areas. Consequently, anychange in a work area pattern by customers needs usually involves acomplete change in tooling. Furthermore, tool metals may not have longlife under conditions of rapid wear at working surfaces so that in manyinstances total tool renewal becomes necessary.

GENERAL REQUlREMENTS FOR TOOL STRUCTURE The structure which couplesultrasonic energy from the acoustic source (piezoelectric ormagnetostrictive transducer) to the material to be processed mustsatisfy several requirements:

1. Provide a sufficiently large output area to encompass the workpiecelocations to be treated.

2. Provide whatever contours are necessary to provide concentration ofsonic energy so that the required vibration amplitude will be availableat the work locations.

3. The material must have sufficiently high strength to withstand highstresses present along the contoured sections.

4. The material must have sufficiently good wear resistance to withstandabrasion at the work faces.

According to prior art, structures are fabricated from one piece ofmetal and at least the first three of the above requirements must be metby this material. Un less the work areas can be provided withwear-resistant inserts, all four requirements must be met. in caseswhere a large work area must be handled, and high amplitude is required,this means that the structure (or horn) must be made of titanium ormonel, materials which are both expensive as raw materials and difficultto machine.

In some cases, it may be very difficult or impossible to provide thecontours necessary to produce the vibra' tion amplitude required at thework areas.

In the present invention, the requirements to be satistied are dividedbetween a tool holder horn and one or more rigid tool member horns whichtaken together make up a rigid horn assembly.

The new tool holder provides for locating the tool members at thenecessary points across the area. It has relatively low stresssituations, no location of wear, and may be made of cheap, easilymachineable materials such as aluminum. It does not require elaboratecontours to be generated.

The new tool members deliver the ultrasonic energy to the material beingprocessed, and include whatever contours are required to produce thevibration amplitude necessary to do the work. Contours may be aselaborate as needed to give the required amplitude, high stress pointsmay be present, and high wear conditions may be present at the workface. Special materials such as titanium 6Al-4V may be required, andthese metals are both expensive and difficult to machine. The size ofthese tool members can be held to a minimum, proportionate to the inputand output areas required to couple the energy, thus material costs andmachining time are held down.

in practically all cases, at least part of the new tool member can beround in section so that full use may be 3 nade of contouring techniquesto provide amplitude nagnification.

ADVANTAGE OF THE INVENTION The present invention to be hereinafterdescribed nakes possible an ultrasonic rigid horn assembly havngenhanced functional adaptability, whose pattern of onic applicator workareas may usually be modified vithout requiring a completely newstructure. For one hing, a great advantage of a rigid horn assemblyemiodying the present invention resides in the fact that he tool holdermay be a body having flat or cylindrical iuter surfaces and issusceptible to accurate economi- :al machining. The sonic transmissioncharacteristics if such new tool holder portion may be controlled ac-:urately and will remain unchanged throughout the 'arious tooltransformations which the invention pernits.

The new tool holder must be longitudinally resonant o a desiredoperating frequency range and has its out )ut end portion or has itsentire body portion shaped or :onstructed in such a manner as toaccommodate a de- III'ECI number of or pattern of rigid tool members.These vool members similarly must be longitudinally resonant 1nd if morethan one are used, are respectively adapted .0 receive sonic energy fromthe tool holder and apply t to work areas. The number and pattern oftool memaer positioning may be changed easily without disturbng the toolholder design whose shape and dimensions are adapted to providedifferent patterns of work areas.

Each tool member is rigid and is individually attached to the toolholder to project from the output end thereof. The attaching means isadapted to be detachable and will include a threaded stud or bolt ofsuitably strong material, usually specially strong steel.

The attaching means itself may include tapped recesses or holesextending into the output end of the tool holder and/or longitudinalbores or holes extending parallel to the axis of the tool holder butlaterally offset therefrom, such bores preferably each having aninternal shoulder against which the enlarged head of a steel bolt may beseated. The tapped recesses or holes and- /or longitudinally disposedbores or holes may be disposed in any desired pattern so that any one ormore tool members may be used in different patterns and spacingarrangements. In all cases, it is preferred to limit the number, spacingand depth of tapped recesses and/or longitudinal bores to minimizesubstantial changes in the sonic transmission characteristics such asresonance and internal reflections of the tool holder between the inputand output thereof. It will generally be desirable to have the toolholder output area sufficiently great to accommodate a number of toolpositions in a desired pattern. In all cases, however, the transversetool holder dimensions must be chosen and proportioned with respect tothe overall length to produce the desired longitudinal mode ofacoustical resonance, with undesired modes minimized so that the toolmembers can produce the desired action on the work areas.

Another substantial advantage obtainable with the invention is thepossibility of having tool members so inclined that their longitudinalaxes are non-parallel to the tool holder axis by a small angle thusproviding a working field which may be somewhat larger or somewhatsmaller than the working field obtainable when the tool member and toolholder axes are parallel.

Other advantages will become apparent later with a more detaileddescription of the invention.

BRIEF DESCRIPTION OF DRAWINGS The invention will be described inconnection with the drawings wherein FIG. 1 is an elevation of a rigidhorn assembly [embodying the present invention] FIG. 1A is a bottom viewshowing the rigid horn assembly of FIG. 1 to illustrate a pattern oftool members.

FIG. 2 is an elevation of a modified form of rigid horn assembly whereincertain tool members are dimensioned differently to provide differentvibration amplitudes.

FIG. 2A is a bottom view of the rigid horn assembly illustrated in FIG.2 showing the arrangement of tool members.

FIG. 3 is an elevation of a still further modified form of the inventionillustrating an arrangement of tool member tips at different levels.

FIG. 3A is a bottom view of the rigid horn assembly illustrated in FIG.3.

FIG. 4 is an elevation of a still further modified form of rigid hornassembly, this showing different means for attaching tool members to thetool holder.

FIG. 4A is a bottom view of the tool member arrangement illustrated inFIG. 4.

FIG. 5 is an elevation of a still further modified form of a rigid hornassembly embodying the present invention, this illustrating II lineararrangement of tool members.

FIG. SA is a bottom view of the tool member arrangement of the structureillustrated in FIG. 5.

FIG. 6 is an elevation of a tool holder I: embodying the presentinvention 1 showing a pattern of recesses for tool member attachment.

FIG. 6A is a bottom view showing the arrangement of recesses.

FIG. 7 is an elevation of a still] further modified form of rigid hornassembly embodying the present invention. this illustrating tool membersdiverging at a slight angle to the tool holder axis rather than beingparallel.

FIG. 7A shows a modification of the form of the invention illustrated inFIG. 7.

FIG. 7B is a detail of FIG. 7A on line 78-78.

FIG. 8 is a still further modified form of a rigid horn assemblyembodying the present invention showing two tool members havingdifferent lengths, the two tool members having different contours tomaintain equality of dimensions in acoustical half wavelengths.

DETAILED DESCRIPTION OF THE INVENTION The new rigid horn assembly I:embodying the present invention II consists essentially of tool holder10 and one or more tool members 11, 11A, 118, etc. Tool holder 10 ispreferably of metal having appropriate accoustical and strengthproperties and may, for example, be of certain grades of aluminum,titanium, or the like. As examples, an aluminum alloy 7075-T65l can beused. In case of titanium. an alloy known as 6Al-4V may be used.

Tool holder 10 has its length equal to an integral number of halfwavelengths at the operating frequency to be used. As a rule, a singlehalf wavelength may be used. For a five inch diameter tool holder ofaluminum 7075-T65l for example, and using 20KHz, a length of 4.345inches may be used. This length is an actual example and it isunderstood that different lots of material may vary in acousticproperties, so the length may depart slightly from the value given. Onecommon shape for tool holder is cylindrical, although, a rectangular orpolygonal shape may be used.

It is understood that the requirement for substantial area at output end10A of tool holder 10 is dictated by the desirability of having toolmembers in desired number and spacing carried at such end. Tool holder10 is preferably proportioned so as to avoid change in vibrationamplitude from the input end 108 of tool holder 10 to the output end10A. End 108 of tool holder 10 is adapted to be coupled to one or moresources of sonic energy. This is most simply accomplished by havingtapped recess 10C for each source extending into the tool holder andpreferably symmetrically disposed with respect to the tool holder axis.In order to attach a source of sonic energy, a steel stud may be screwedinto recess 10C, the steel stud being strong enough to withstand thevarious stresses and strains to which it may be subjected. For example,a sonic generator of the piezoelectric or magnetostrictive type may beused, the output being directly coupled to tool holder 10 or through anintermediate resonant coupling member.

One or more tool members 11; 11A; 118 etc. may be coupled to tool holder10 at output face 10A. Referring to tool member 1 l, as an example, thisconsists of input portion 13 and reduced tool member portion 14 as anextension thereof. In the particular example given, tool member 11 as awhole will have an overall length of one-half wavelength with inputportion 13 and tool member portion 14 being respectively one-quarterwavelength each. It is understood that the physical length of the entiretool member may be different from the physical length of tool holder 10depending, of course, upon the nature and contour of the material used.

The designation of one-half wavelength for the overall tool member 11 isexemplary. It is understood that either the tool holder or the toolmember, or both, may have one or more integral number of acoustical halfwavelengthsfln particular, the possibility of using tool members longerthan one-half wavelength may be desirable. There is no particulararrangement or number of tool members necessary for use at the outputpart 10A of the tool holder.

Referring to FIG. 1A, it will be observed that a symmetrical arrangementof four tool members is provided. Each tool member is rigidly secured totool holder 10 by means of threaded steel stud 16. It is important thatstud 16 be of a sufficiently strong material and properly dimensioned towithstand the vibratory stresses. Stud 16 may be integral with a toolmember, if the tool is of sufficiently strong metal, such as titanium.The stud will in all cases extend into tapped recesses or holes inbottom face 10A of tool holder 10.

While four tool members are shown, it is not necessary that all toolmembers be used or be positioned in the tool holder. In fact, there isnothing magic about the number of tool members and the number may be asdesired. This is also true of the pattern in which the tool memberaccommodating recesses are disposed. While the number and spacing oftool member accommodat-' ing recesses in face 10A of tool holder 10 mayvary within wide limits, it is essential that the volume of metalremoved from all the recesses be small enough in comparison to the massof the entire tool holder so that the general transmissioncharacteristics of tool holder 10 for conducting sonic energy from face108 to face 10A be unimpaired. Thus, if an excessively large num ber oftapped recesses is to be provided, it may be nec essary to compensate achange in transmission charac teristics by adjusting the length of thetool holder or th transverse dimensions of the tool holder or both.

No attempt is made to show the detailed structure c tool member portion14 at the tip thereof since suc details are well known, depending uponthe work effec to be created. It should be noted that the various tocmembers extending downwardly from tool holder 1 are rigid members andthat the entire assembly of toc holder and tool members together withthe source c sonic energy, such as transducer, may be handled iconventional fashion by supporting in a press so tha one or more toolmembers have their working end pressed against the work piece to betreated. The actuz support of the entire assembly of transducer, tocholder 10 and the tool members, may be on the trans ducer, or on toolholder 10 or both. If the tool holder i to be supported, then asupporting nodal mount aroun the middle of tool holder 10 can beprovided. At thi region of the tool holder, the longitudinal amplitude cthe sonic energy is substantially zero. The same is tru for transducersso that mounts for the nodal regions (I transducers and tool holders maybe joined.

Referring now to FIG. 2, the tool member is substar tially similar tothat illustrated in FIG. 1 except the tools 11A are shown as being ofgreater transvers area than 11 and 1113. Such an arrangement permitgreater amplitude to be delivered at the working end c the tool memberas may be required in certain ir stances.

Referring now to FIG. 3, output face 10A has slotte portion 10A foraccommodating tool members 11A sl long as the offset of slotted portion10A with respect t 10A is small in terms of wavelength (as for example ithe assumed case a difference of about one-quarter an inch may betolerated), the rigid horn assembly wi function generallysatisfactorily. Such an arrangemer may be desirable where material to beworked upon re quires a stepped arrangement of tool member workin faces.As is illustrated in FIG. 3A, slotted portion 10A extends straightacross the end face of tool holder 10. is not necessary that slot 10Aextend all the way acros and instead only one of the face members HA mayb thus longitudinally offset.

Referring now to FlG. 4, a different arrangement tool member attachmentto tool holder 10' is illu: trated. In this instance, instead of tappedrecesses in th tool holder, there may be a pattern of passages or holelongitudinally of the tool holder and generally parallt to the axis butlaterally offset therefrom. Such paSSagt have enlarged bore portions 20having shoulders 2 and reduced bore portions 22 extending longitudinalof tool holder 10'. Bolts 23 having enlarged heads 23. can extend asillustrated with threaded portions 24 e: tending into and cooperatingwith threaded recesses i tool member 26. Tool member 26 may have asuitab workable shape. As shown here, enlarged head 23A bolt 23 isprovided with a suitably shaped hex recess ft engagement by a hex shapedrod to be used as wrench. The diameters of bores 20 and 22 and shouldt21 are all relatively proportioned so that each to member retaining boltwill not be excessively stressel Again as with tapped recesses or holesin the to holder previously described, it is essential that the nun berof passages or holes 20 and 22 in a tool holder t such that thetransmission characteristics of the entii ol holder remain constant. Inthis particular modifiition, it is clear that the volume of metalremoved for lCIl tool member position is much greater than in the'evious instances where only a blind tapped recess is .ed. However. thecompensation for the removal of etal may be readily provided bycontrolling the lateral id longitudinal dimensions of the tool holder.The arngement of bolts as illustrated here in FIG. 4 is such at accessto the top face 108 of tool holder is reiired. In some instances, themounting of the rigid irn assembly, transducer accessories variousaccefo- :s may make access difficult. It is understood, there- )m, thatwhile the two arrangements illustrated in G. 4 and FIGS. 1 to 3 forexample with regard to tool ember attachment to a tool holder areequivalent, ie may for certain purposes be more convenient than e other.Referring to FIG. 4A, it will be noted that tool mem- :r 26 has the topportion of rectangular shape. Either 1e or two bolts 23 may be used foreach tool member, :pending upon requirements for a particular job. Therangement of tool members in this particular tool )ICICI' may vary sothat more or less than two tool embers are used. Referring to FIG. 5, amodified tool member arrangeent, each of which may have a tapered shape,is illusated. In this particular modification, as illustrated in G. 5A,two lines of tool members at right angles to lCh other are illustrated.It is not necessary that every ol member position be filled with a toolmember and is not even necessary that each tool member be of the peredtype. Referring now to FIG. 6, an arrangement of recesses a tool holderis shown wherein such recesses which e tapped are aligned along lineswhich extend in vari- .IS directions making possible a large number ofpossie tool member arrangements. It is understood that is particulararrangement of recesses or holes may be placed by through passages orholes in a tool holder milar to FIG. 4. Referring now to FIG. 7, a toolholder is illustrated herein tool members have their axes disposed at aight angle to the tool holder axis. Thus, two or more ol members may bearranged in this fashion, it being \derstood that the various angles atthe output faces the tool holder must be small. By having the toolmember axes inclined to be nontrallel to the tool holder axis, thetotality of all work ea patterns may be made smaller or larger than theitire work area of parallel tool member arrangements. In FIG. 7, therigid horn tool members diverge. In IG. 7A, the tool members converge.In both cases, the )posing tool holder and tool member surfaces must beat and true. Where the entire tool holder face is coni- II, it isnecessary to machine flat areas against which tool member may fit, assuggested in FIG. 7B. The -ol members may be bolted, brazed or welded inace. In FIG. 7A, the convergence of the tool members tips ay requiremachining after tool members have been rt in place on a tool holder.This may involve shaping le tool member tips to Straighten out theworking axis )rmal to the work. Referring now to FIG. 8, an arrangementis shown herein two differently dimensioned tool members are :ilized,one tool member being thicker and longer an the other. This arrangementcan be obtained by )ntrolling the nature of the contour for the tool. Itis 8 understood, ofcourse, that in each case each tool must have alength equal to one or more integral half wavelengths.

In a broad sense, a tool holder and tool member may each be consideredas a horn so that an entire assembly may be designated as a rigid hornassembly.

An entire assembly of tool holder and tool member horns embodying thepresent invention is substantially rigid at the tool member ends eventhough resilient nodal mounting means for tool holder and/or trans ducermeans are provided. Resilient mounts are desirable because of theirefficiency.

What is claimed is:

I: 1. An ultra-sonic tool system for industrial processing with acousticenergy, said system comprising an elongated, straight, rigid, unitarytool holder of rigid material having a longitudinal axis and a length ofan integral number of half-wave lengths at the operating frequency, thetransverse dimensions being so propor tioned to the length thereof as tominimize undesired modes of transmission other than along the toolholder length, said tool holder having only two ends shaped to providefinished flat sonic energy input and output areas, the tool holderproviding a common transmission path for all sonic energy from the inputto the output thereof, threaded means at the input end for coupling atleast one source of sonic energy thereto; at least two, elongated, rigidtool members laterally spaced from each other rigidly secured directlyto a sonic output area of the tool holder, each tool member having atone end a sonic input area conforming to a sonic tool holder output areain the secured positions of the tool holder and tool members, each toolmember having a sonic energy working output tip at its other end, thetool holder output area being great enough to accommodate a plurality oflaterally offset, secured tool members arranged to create a desiredpattern of work areas, each tool member having a length of an integralnumber of half-wave lengths; whereby said tool holder material may beselected on a basis of acoustic properties, cost, and ease of machiningand the tool member mate rial may be selected on a basis of acousticproperties and toughness for working life, said tool holder and toolmembers being each resonant to the acoustic energy so that efficienttransmissions of sonic energy to the work areas result, each tool memberbeing susceptible to individual design with regard to tool membercontours, amplitude of sonic energy at a work area and physical lengthof a tool member; the machining problem of the tool holder beingdistinct from any problem of machining a tool member, said tool systembeing sufficiently rigid so that it may be pressed against work withoutaccessories for guiding tool members] 2. The construction according toclaim 1 wherein said tool holder has a plurality of holes extending fromat least one output area thereof inwardly toward the input end thereofand wherein threaded means are provided for rigidly securing a toolmember to said holder at a desired hole] I 3. The construction accordingto claim 2, wherein threaded metal studs for rigidly securing said toolmem bers to the output of said tool holder are provided] I: 4. Theconstruction according to claim 2, wherein said tool holder has aplurality of longitudinal bores extending parallel to and laterallyoffset from the axis of the tool holder, and a bolt for rigidly securinga tool member to the tool holder at a bore.

I: 5. The construction according to claim 1, wherein the tool holder isshaped so that the transverse dimensions remains substantially constantalong the length of such holder] 6 An ultrasonic tool system forindustrial processing with acoustic energy, said system comprising anelongated, straight, rigid, unitary tool holder of rigid material havinga longitudinal axis and a length of an intergral number of half-wavelengths at the operating frequency, the transverse dimensions being soproportioned to the length thereof as to minimize undesired modes oftransmission other than along the tool holder length, said tool holderhaving only two ends shaped to provide finished flat sonic energy inputand output areas, the tool holder providing a common transmission pathfor all sonic energy from the input to the output thereof, threadedmeans at the input end for coupling at least one source of sonic energythereto; at least two, elongated, rigid tool members laterally spacedfrom each other each rigidly secured directly to a sonic output area ofthe tool holder, each tool member having at one end a sonic input areaconforming to a sonic tool holder output area in the secured positionsof the tool holder and tool members, each tool member having a sonicenergy working output tip at its other end, the tool holder output areabeing great enough to accommodate a plurality of laterally offsetsecured tool members arranged to create a desired pattern of work areas,each tool member having a length of an integral number of half-wavelengths, said tool holder and tool members being each resonant to theacoustic energy so that efficient transmissions of sonic energy to thework areas result, each tool member being susceptible to individualdesign with regard to tool member contours, amplitude of sonic energy ata work area and physical length of a tool member, said tool system beingsufficiently rigid so that it may be pressed against work withoutaccessories for guiding tool members, at least one of said tool membershaving at least part of its length of a substantially differenttransverse dimension than corresponding parts of other tool members sothat vibration amplitude differs from other tool members at the workareas.

7. An ultra-sonic tool system for industrial processing with acousticenergy, said system comprising an elongated, straight, rigid, unitarytool holder of rigid material having a longitudinal axis and a length ofan integral number of half-wave lengths at the operating frequency, thetransverse dimensions being so proportioned to the length thereof as tominimize undesired modes of transmission other than along the toolholder length, said tool holder having two ends shaped to providefinished flat sonic energy input and output areas, the tool holderproviding a common transmission path for all sonic energy from the inputto the output thereof, threaded means at the input end for coupling atleast one source of sonic energy thereto; at least two, elongated, rigidtool members laterally spaced from each other rigidly secured directlyto sonic output areas of the tool holder, each tool member having at oneend a sonic input area conforming to a sonic tool holder output area inthe secured positions of the tool holder and tool members, each toolmember having a sonic energy working output tip at its other end, thetool holder output area being great enough to accommo- LII 0 member,said tool system being sufficiently rigid so tho it may be pressedagainst work without accessories fo. guiding tool members, at least oneof said tool member. having its working end at a level different fromthat Q other tool members.

8. The system according to claim 7, wherein said too holder has aportion of its output face at a level dijferen. from other portions sothat even if similarly dimensionet tool members are used, the workingends of such too members are at different levels, the difference inlevel a. the output of the tool holder being small in comparison tn theoperating wavelength.

9. An ultra-sonic tool system for industrial processing with acousticenergy, said system comprising an elongated, straight, rigid, unitarytool holder of rigid materia. having a longitudinal axis and a length ofan integral number of half-wave lengths at the operating frequency thetransverse dimensions being so proportioned to the length thereof as tominimize undesired modes of transmission other than along the toolholder length, said tool holder having two ends shaped to providefinished flat sonic energy input and output areas, the tool holderproviding a common transmission path for all sonic energy from the inputto the output thereof, threaded means at the input end for coupling atleast one source of sonic energy thereto; at least two, elongated, rigidtool members laterally spaced from each other rigidly secured directlyto a sonic output area of the tool holder, each tool member having atone end a sonic input area conforming to a sonic tool holder output areain the secured positions 0] the tool holder and tool members, each toolmember having a sonic energy working output tip at its other end, thetool holder output area being great enough to accommodate a plurality oflaterally offset, secured tool members arranged to create a desiredpattern of work areas, each tool member having a length of an integralnumber 0) half-wave lengths, said tool holder and tool members beingeach resonant to the acoustic energy so that efficient transmissions ofsonic energy to the work areas result, each tool member beingsusceptible to individual design with regard to tool member contours,amplitude of sonic energy at a work area and physical length of a toolmember, said tool system being sufficiently rigid so that it may bepressed against work without accessories for guiding tool members, atleast two sonic flat output area portions of the tool holder lying indifferent non-parallel planes so that secured tool members have theirrespective lengths in non-parallel relation, the angular departure fromparallelism being small.

I0. The system according to claim 9, wherein the tool members converge.

l I The system according to claim 9, wherein the tool members diverge.

6. An ultra-sonic tool system for industrial processing with acousticenergy, said system comprising an elongated, straight, rigid, unitarytool holder of rigid material having a longitudinal axis and a length ofan intergral number of halfwave lengths at the operating frequency, thetransverse dimensions being so proportioned to the length thereof as tominimize undesired modes of transmission other than along the toolholder length, said tool holder having only two ends shaped to providefinished flat sonic energy input and output areas, the tool holderproviding a common transmission path for all sonic energy from the inputto the output thereof, threaded means at the input end for coupling atleast one source of sonic energy thereto; at least two, elongated, rigidtool members laterally spaced from each other each rigidly secureddirectly to a sonic output area of the tool holder, each tool memberhaving at one end a sonic input area conforming to a sonic tool holderoutput area in the secured positions of the tool holder and toolmembers, each tool member having a sonic energy working output tip atits other end, the tool holder output area being great enough toaccommodate a plurality of laterally offset secured tool membersarranged to create a desired pattern of work areas, each tool memberhaving a length of an integral number of halfwave lengths, said toolholder and tool members being each resonant to the acoustic energy sothat efficient transmissions of sonic energy to the work areas result,each tool member being susceptible to individual design with regard totool member contours, amplitude of sonic energy at a work area andphysical length of a tool member, said tool system being sufficientlyrigid so that it may be pressed against work without accessories forguiding tool members, at least one of said tool members having at leastpart of its length of a substantially different transverse dimensionthan corresponding parts of other tool members so that vibrationamplitude differs from other tool members at the work areas.
 7. Anultra-sonic tool system for industrial processing with acoustic energy,said system comprising an elongated, straight, rigid, unitary toolholder of rigid material having a longitudinal axis and a length of anintegral number of half-wave lengths at the operating frequency, thetransverse dimensions being so proportioned to the length thereof as tominimiZe undesired modes of transmission other than along the toolholder length, said tool holder having two ends shaped to providefinished flat sonic energy input and output areas, the tool holderproviding a common transmission path for all sonic energy from the inputto the output thereof, threaded means at the input end for coupling atleast one source of sonic energy thereto; at least two, elongated, rigidtool members laterally spaced from each other rigidly secured directlyto sonic output areas of the tool holder, each tool member having at oneend a sonic input area conforming to a sonic tool holder output area inthe secured positions of the tool holder and tool members, each toolmember having a sonic energy working output tip at its other end, thetool holder output area being great enough to accommodate a plurality oflaterally offset secured tool members arranged to create a desiredpattern of work areas, each tool member having a length of an integralnumber of half-wave lengthss, said tool holder and tool members beingeach resonant to the acoustic energy so that efficient transmissions ofsonic energy to the work areas result, each tool member beingsusceptible to individual design with regard to tool member contours,amplitude of sonic energy at a work area and physical length of a toolmember, said tool system being sufficiently rigid so that it may bepressed against work without accessories for guiding tool members, atleast one of said tool members having its working end at a leveldifferent from that of other tool members.
 8. The system according toclaim 7, wherein said tool holder has a portion of its output face at alevel different from other portions so that even if similarlydimensioned tool members are used, the working ends of such tool membersare at different levels, the difference in level at the output of thetool holder being small in comparison to the operating wavelength.
 9. Anultra-sonic tool system for industrial processing with acoustic energy,said system comprising an elongated, straight, rigid, unitary toolholder of rigid material having a longitudinal axis and a length of anintegral number of half-wave lengths at the operating frequency, thetransverse dimensions being so proportioned to the length thereof as tominimize undesired modes of transmission other than along the toolholder length, said tool holder having two ends shaped to providefinished flat sonic energy input and output areas, the tool holderproviding a common transmission path for all sonic energy from the inputto the output thereof, threaded means at the input end for coupling atleast one source of sonic energy thereto; at least two, elongated, rigidtool members laterally spaced from each other rigidly secured directlyto a sonic output area of the tool holder, each tool member having atone end a sonic input area conforming to a sonic tool holder output areain the secured positions of the tool holder and tool members, each toolmember having a sonic energy working output tip at its other end, thetool holder output area being great enough to accommodate a plurality oflaterally offset, secured tool members arranged to create a desiredpattern of work areas, each tool member having a length of an integralnumber of half-wave lengths, said tool holder and tool members beingeach resonant to the acoustic energy so that efficient transmissions ofsonic energy to the work areas result, each tool member beingsusceptible to individual design with regard to tool member contours,amplitude of sonic energy at a work area and physical length of a toolmember, said tool system being sufficiently rigid so that it may bepressed against work without accessories for guiding tool members, atleast two sonic flat output area portions of the tool holder lying indifferent non-parallel planes so that secured tool members have theirrespective lengths in non-parallel relation, the angular departure fromparallelism being small.
 10. The system according to claim 9, whereinthe tool members converge.
 11. The system according to claim 9, whereinthe tool members diverge.